Hi,

I have been rotary milling/carving PIR insulation foam (expanded polystyrene or EPS) successfully but recently trying to cut Styrofoam (extruded polystyrene XPS), the same milling bits were struggling to not overheat. Blue Styrofoam is denser than PIR insulation or certainly the 120mm Dow floormate Styrofoam.

I wondered if using an oscillating tangential knife unit would be better than a rotary bit. This particular job entails cutting through 120mm material, preferably in a single deep cut.

My question is, which method would better suit the material and what mill ends/ saws/knife bits would be best (not withstanding the feeds and speeds settings as well)

Any experience of Styrofoam cutting and carving most welcome.

Thanks